Modular solar panel mounting clamps

ABSTRACT

Clamps for mounting frameless, glass paneled, thin-film solar modules on slant-roof, flat roof, or ground-mounted solar systems. The clamps of the present invention can be also adapted to use with existing roof rail systems or other mounting brackets.

REFERENCE TO RELATED APPLICATIONS

This application claims one or more inventions which were disclosed in Provisional Application Number 61/031,244, filed, entitled “Modular Solar Panel Mounting Clamps”. The benefit under 35 USC § 119(e) of the United States provisional application is hereby claimed, and the aforementioned application is hereby incorporated herein by reference.

BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention relates generally to a mounting system for solar panels. Specifically, the present invention relates to modular mounting clamps for installing frameless, thin-film solar panels on a rooftop or on the ground.

2. Description of Related Art

A solar cell or photovoltaic cell is a device that converts light energy into electrical energy by the photovoltaic effect. Traditionally the photovoltaic cells are made from crystalline silicone. Recently a new thin-film manufacturing process enables the production of photovoltaic cells using amorphous silicon at a much more reduced cost. Thin-film photovoltaic cells use less of the raw material (silicon or other light absorbers) compared to wafer based solar cells, leading to a significant price drop per kWh. These thin-film photovoltaic cells are produced as frameless, glass panels. The existing mounting systems designed to mount framed photovoltaic cells do not fit the requirements for the mounting thin-film photovoltaic cells on the ground or on rooftop.

There exists a demand for a solar panel mounting hardware specifically designed for the frameless, glass paneled, thin-film photovoltaic cells that reduces the cost and labor requirement of installation.

SUMMARY OF THE INVENTION

In a first embodiment, the invention is directed to an apparatus for mounting frameless solar panels wherein the apparatus includes an upper plate, having a top plane and a bottom plane and an aperture proximal to a first end, a lower plate, having a top plane and a bottom plane and an aperture proximal to a first end. A spacer is included having a top plane, a bottom plane, a first vertical surface and a second vertical surface, wherein the spacer has a centrally located aperture therethrough. The apparatus further includes a fastener system, a plurality of cushions, brackets having a long axis with a top plane and a bottom plane, wherein the top plane is in contact with the bottom plane of the lower plate, and a rail insert fastener system. The aperture in the upper plate, spacer, and lower plate align to form a passage.

The bottom plane of the upper plate and the upper plane of the lower plate have a groove configured to the top plane and the bottom plane of the spacer.

The bracket has a long axis which terminates at a first notched end and a second notched end, wherein the first notched end is on the top plane and the second notched end is on the bottom plane of the long axis. The first notched end and the second notched end each have an elongated opening parallel to the direction of the long axis of the bracket. The brackets have assembly apertures on the long axis proximal to the first notched end and the second notched end.

The fastener system comprises a nut and bolt, wherein the bolt of the fastener system traverses the aperture of the upper plate, lower plate, spacer and assembly aperture of the bracket. The nut of the fastener system is in contact with the bottom plane of the bracket when a frameless solar panel is secured.

The first end of the upper plate and the first end of the lower plate are aligned when a solar panel is secured. The bottom plane of the upper plate, the top plane of the lower plate and the first vertical surface of the spacer have a cushion attached thereto.

In another embodiment, the invention is directed to an apparatus for mounting frameless solar panels including an upper plate having a top plane and a bottom plane and a centrally located aperture, a lower plate having a top plane and a bottom plane having centrally located aperture. A spacer is included having a top plane, a bottom plane, a first vertical surface and a second vertical surface, wherein the spacer has a centrally located aperture therethrough. In addition, the apparatus includes a rail insert fastener system and a plurality of cushions, whereby the aperture in the upper plate, spacer, and lower plate align to form a passage.

The bottom plane of the upper plate and the upper plane of the lower plate have a groove configured to the top plane and the bottom plane of the spacer. The bottom plane of the upper plate, the top plane of the lower plate and the first and second vertical surfaces have a cushion attached thereto. The rail insert fastener system comprises a fastener and an insert, wherein the fastener traverses the passage and is secured to the insert.

In another embodiment, the invention is directed to a process for mounting frameless solar panel modules comprising the steps of a) preparing a first solar module panel comprising the steps of i.) inserting a solar panel into an apparatus for mounting frameless solar panels wherein the apparatus comprises an upper plate having a top plane and a bottom plane having an aperture proximal to a first end, a lower plate having a top plane and a bottom plane having an aperture proximal to a first end, a spacer having a top plane, a bottom plane, a first vertical surface and a second vertical surface, wherein the spacer has a centrally located aperture therethrough, a fastener system, a plurality of cushions, a bracket having a long axis with a top plane and a bottom plane, wherein the bracket has a long axis which terminates at a first notched end and a second notched end, wherein the first notched end is on the top plane and the second notched end is on the bottom plane of the long axis, wherein the first notched end and the second notched end has an elongated opening in the direction of the long axis of the bracket, wherein the brackets have assembly apertures parallel to the long axis proximal to the first notched end and the second notched end, wherein the top plane of the bracket is attached to the bottom plane of the lower plate and a rail insert fastener system, whereby the aperture in the upper plate, spacer, and lower plate align to form a passage, ii.) traversing the passage formed by the aperture in the upper plate, spacer, lower plate, and assembly aperture with a first member of the fastener system, and iii.) compressing the upper plate, the lower plate and the bracket by attachment of a second member of the fastener system to the first member of the fastener system.

The process further includes b) aligning the assembly apertures of a first notched end of a bracket of the first module to a second notched end of a bracket of a second module prepared by step a., c) traversing the elongated openings with a first member of the rail insert fastener system; and d) securing the first notched end of a bracket of a first module to a second notched end of a second module by attachment of a second member of the rail insert fastener system within a rail.

BRIEF DESCRIPTION OF THE DRAWING

FIG. 1 is a side view of a pair of apparatus of a first embodiment of the present invention with inserted solar panels, installed on a rail;

FIG. 2 is a perspective view of a pair of apparatus wherein a first apparatus is assembled and a second apparatus is illustrated in an exploded view prior to installation on a rail;

FIG. 3 is a perspective view of the bracket of the present invention;

FIG. 4A is a plan view of a perpendicular bar bracket support configuration;

FIG. 4B is a plan view of a crossing bar bracket support configuration;

FIG. 5 is a cross-sectional view of a second embodiment of the apparatus of the present invention installed on a rail;

FIG. 6 is an exploded view of the apparatus of the embodiment of FIG. 5 prior to installation on a rail;

FIG. 7 is a perspective view of the embodiment of FIGS. 1 and 2 having an installed solar panel and installed on a rail.

FIG. 8 is a perspective view of the embodiment of FIGS. 5 and 6 having an installed solar panel and installed on a rail.

DETAILED DESCRIPTION OF THE INVENTION

The present invention teaches clamp designs for mounting frameless, glass paneled, thin-film solar modules on slant-roof, flat roof, or ground-mounted solar systems. A first embodiment of the present invention is a clamp designed to act as an adapter to attach thin-film solar modules to roof rail systems already available from Professional Solar Products, or UniRac® mounting systems and others. The clamp provides a means to attach universally to frameless panels from any manufacturer using readily available standard mounting hardware. The advantages of this clamp design are that it is significantly more cost effective, easy to manufacture, easy to install, and provides an optimal means to attach the panel while providing maximum support and gripping ability. Minor modifications can be made to this clamping device to accommodate different sizes of glass or gripping pressure by only adding different sized shims within the clamp. This system with adapter bar can be used on both the sloped roof system or on ground mounting systems.

Referring to FIGS. 1 and 2, a pair of apparatus 100 of the first embodiment of the invention is illustrated installed on a rail 1000. Referring to FIG. 2, the pair of apparatus of the first embodiment of the invention is illustrated prior to installation on a rail 1000. In FIG. 2, a first apparatus 100 is illustrated assembled for receipt of a solar panel 2000 and a second apparatus 100 is illustrated prior to assembly. Each apparatus 100 includes an upper plate 102 having a top plane 102A and a bottom plane 102B, having an aperture 102C proximal to a first end 102D and a lower plate 104, having a top plane 104A and a bottom plane 104B, having an aperture 104C proximal to a first end 104D. A spacer 106 is included having a top plane 106A, a bottom plane 106B, a first vertical surface 106C and a second vertical surface 106D; wherein the spacer 106 has a centrally located aperture 106E therethrough. In addition, in this embodiment the invention includes a bracket 108 having a long axis 108A with a top plane 108B and a bottom plane 108C, wherein the top plane 108B is in contact with the bottom plane 104B of the lower plate 104.

The bottom plane 102B of the upper plate 102 and the upper plane 104A of the lower plate 104 each have a groove 110, 112 configured to the top plane 106A and the bottom plane 106B of the spacer 106. The grooves reduce the amount of movement of the spacer 106 during assembly and installation. As it is will be recognized by those skilled in the art that the components of the apparatus 100 can be of one piece construction or multiple pieces, the grooves 110, 112 will allow additional support and strength. The upper plate 102, bottom plate 104 and spacer 106 are composed of materials such as aluminum or galvanized steel.

Referring to FIGS. 1, 2 and 3, each bracket 108 has a long axis 108A which terminates at a first notched end 108D and a second notched end 108E, wherein the first notched end 108D is on the top plane 108A and the second notched end 108E is on the bottom plane 108B of the long axis 108A. The first notched end 108D and the second notched end 108E have elongated openings 108D1, 108E1 parallel to the direction of the long axis 108A of the bracket 108. The brackets 108 have assembly apertures 108F, on the long axis 108A proximal to the first notched end 108D and the second notched end 108E.

The aperture in the upper plate 102C, spacer 106E, lower plate 104C and assembly aperture 108F align to form a passage 111. A fastener system 112 can be of various securing mechanism but will most likely includes a nut 112A and bolt 112B (partially shown in phantom in FIG. 1), wherein the bolt 112B of the fastener system 112 traverses the passage 111 and is secured by the nut 112A. The nut 112B of the fastener system 112 is in contact with the bottom plane 108C of the bracket 108 when a frameless solar panel 2000 is secured in the apparatus 100. The first end of the upper plate 102D and the first end of the lower plate 104D are aligned when a solar panel is secured.

A plurality of cushions 114 are used to contact the solar panel 2000 upon installation so as to prevent damage. The cushions 114 provide a “snug” fit but allow variations in the amount of compression/pressure applied during manual installation. This “variation” allows reduced labor and installation as the objective of the installer is a “snug” fit without any additional measurements needed. The cushions 114 are applied to the bottom plane 102B of the upper plate 102, the top plane 104A of the lower plate 104 and the first vertical surface 106D of the spacer 106 on each apparatus 100, thereby assuring all contact between the apparatus 100 and the solar panels 2000 is via a cushion 114.

A rail insert fastener system 116 can be of various designs which will be effective to secure each apparatus 100 to a standard roof rail 1000 as discussed herein. For example, the fastener system 116 includes a threaded bolt 116A and a rail insert 116B, wherein the threaded bolt 116A can be secured to the rail insert 116B within the standard rail. This allows each “module”, e.g. a solar panel 2000 having an attached apparatus 100 to be secured to the standard rail 1000. The bolt 116A traverses the elongated holes 108D1, 108E1 on the brackets and is secured by a rail insert 116B, as best illustrated in FIG. 1. As best illustrated in FIG. 7, multiple apparatus 100 are shown having an installed solar panel 2000, wherein the apparatus 100 is installed on a rail 1000.

As illustrated in FIGS. 4A and 4B, the mounting brackets 108 are parallel to each other when attached to the solar panels 2000. As illustrated in FIG. 4A, this configuration can be supported and strengthened by a brace 118 which connects the brackets 108. The brace 118 is a bar perpendicular to the brackets 108, wherein each end of the brace 118 connects each bracket 108 attached to a solar panel 2000. As illustrated in FIG. 4B, the system could include two intersecting braces 118 wherein each intersecting brace 118 is attached to brackets 108 attached to a solar panel 2000. Attachment of the brace 118 to the brackets 108 can be by various methods, e.g. adhesive, fasteners or weld.

Additional embodiments of the invention will now be described wherein like parts are numbered with like reference numbers.

A second embodiment of the present invention is designed to mount frameless solar panels of varying thicknesses using a single set of clamps per two adjacent modules The advantages of this embodiment is that it allows for a cost effective means in which to mount the modules on a sloped roof using existing module mounting hardware such as those manufactured by Professional Solar Products, or UniRac®, it is easy to manufacture, easy to install, and provides an optimal means to attach the panel while providing maximum support and gripping ability. This embodiment can be used effectively on sloped roof systems.

Referring to FIGS. 5 and 6, an apparatus 200 is illustrated for mounting frameless solar panels includes an upper plate 202 having a top plane 202A and a bottom plane 202B and a centrally located aperture 202C, a lower plate 204 having a top plane 204A and a bottom plane 204B and a centrally located aperture 204C In addition, a spacer 206 is included having a top plane 206A, a bottom plane 206B, a first vertical surface 206C and a second vertical surface 206D, wherein the spacer 206 has a centrally located aperture 206E therethrough. The aperture in the upper plate 202C, spacer 206E, and lower plate 204C align to form a passage 211.

The bottom plane 202B of the upper plate 202 and the upper plane 204A of the lower plate 204 have a groove configured 210, 212 to the top plane 206A and the bottom plane 206B of the spacer 206. The grooved surfaces 210, 212 ensure a secure fit and limits movement of the spacer 206 during installation of the solar panel 2000.

The apparatus 200 includes a plurality of cushions 214 wherein the bottom plane 202B of the upper plate 202, the top plane 204A of the lower plate 204 and the first and second vertical surfaces 206C, 206D of the spacer 206, have a cushion 214 attached thereto. As in the previous embodiment, the cushions provide a “snug” fit and prevent damage to the solar panel 2000 when installed in the apparatus 200.

Similar to the previous embodiment, a rail insert fastener system 216 can be of various designs which will be effective to secure each apparatus 200 to a standard roof rail as discussed herein. For example, the fastener system 216 includes a threaded bolt 216A and a rail insert 216B, wherein the threaded bolt 216A can be secured to the rail insert 216B within the standard rail 1000 wherein the threaded bolt 216A traverses the passage 211 and is secured to the rail insert 216B. This allows each module to be secured to the standard rail 1000. As best illustrated in FIG. 8, multiple apparatus 200 are shown having an installed solar panel 2000, wherein the apparatus 200 is installed on a rail 1000.

In another embodiment, the invention is directed to a process for mounting frameless solar panel modules comprising the steps of a) preparing a first solar module panel module comprising the steps of i.) inserting a solar panel into an apparatus for mounting frameless solar panels wherein the apparatus comprises an upper plate having a top plane and a bottom plane having an aperture proximal to a first end, a lower plate having a top plane and a bottom plane having an aperture proximal to a first end, a spacer having a top plane, a bottom plane, a first vertical surface and a second vertical surface, wherein the spacer has a centrally located aperture therethrough, a fastener system, a plurality of cushions, a bracket having a long axis with a top plane and a bottom plane, wherein the bracket has a long axis which terminates at a first notched end and a second notched end, wherein the first notched end is on the top plane and the second notched end is on the bottom plane of the long axis, wherein the first notched end and the second notched end has an elongated opening in the direction of the long axis of the bracket, wherein the brackets have assembly apertures parallel to the long axis proximal to the first notched end and the second notched end, wherein the top plane is attached to the bottom plane of the lower plate and a rail insert fastener system, whereby the aperture in the upper plate, spacer, and lower plate align to form a passage, ii.) traversing the passage formed by the aperture in the upper plate, spacer, lower plate, and assembly aperture with a first member of the fastener system, and iii.) compressing the upper plate, the lower plate and the bracket by attachment of a second member of the fastener system to the first member of the fastener system;

The process further includes b) aligning the assembly apertures of a first notched end of a bracket of the first module to a second notched end of a bracket of a second module prepared by step a., c) traversing the elongated holes of the brackets with a first member of the rail insert fastener system; and d) securing the first notched end bracket of a first module to a second notched end of the second module by attachment of a second member of the rail insert fastener system within a rail.

These and other advantages of the present invention will be apparent to those skilled in the art from the foregoing specification. Accordingly, it will be recognized by those skilled in the art that changes or modifications may be made to the above-described embodiments without departing from the broad inventive concepts of the invention. It should therefore be understood that this invention is not limited to the particular embodiments described herein, but is intended to include all changes and modifications that are within the scope and spirit of the invention. Reference herein to details of the illustrated embodiments is not intended to limit the scope of the claims, which themselves recite those features regarded as essential to the invention. 

1. An apparatus for mounting frameless solar panels comprising: an upper plate having a top plane and a bottom plane having an aperture proximal to a first end; a lower plate having a top plane and a bottom plane having an aperture proximal to a first end; a spacer having a top plane, a bottom plane, a first vertical surface and a second vertical surface; wherein the spacer has a centrally located aperture therethrough; a fastener system; a plurality of cushions; a bracket having a long axis with a top plane and a bottom plane, wherein the top plane is in contact with the bottom plane of the lower plate; and a rail insert fastener system, whereby the aperture in the upper plate, spacer, and lower plate align to form a passage.
 2. The apparatus of claim 1, wherein the bottom plane of the upper plate and the upper plane of the lower plate have a groove configured to the top plane and the bottom plane of the spacer.
 3. The apparatus of claim 1, wherein the bracket has a long axis which terminates at a first notched end and a second notched end, wherein the first notched end is on the top plane and the second notched end is on the bottom plane of the long axis.
 4. The apparatus of claim 1, wherein the first notched end and the second notched end have an elongated opening parallel to the direction of the long axis of the bracket.
 5. The apparatus of claim 1, wherein the brackets have assembly apertures on the long axis proximal to the first notched end and the second notched end.
 6. The apparatus of claim 1, wherein the fastener system comprises a nut and bolt, wherein the bolt of the fastener system traverses the aperture of the upper plate, lower plate, spacer and assembly aperture of the bracket.
 7. The apparatus of claim 1, wherein the nut of the fastener system is in contact with the bottom plane of the bracket when a frameless solar panel is secured.
 8. The apparatus of claim 1, wherein the first end of the upper plate and the first end of the lower plate are aligned when a solar panel is secured.
 9. The apparatus of claim 1, wherein the bottom plan of the upper plate, the top plane of the lower plate and the first vertical surface have a cushion attached thereto.
 10. An apparatus for mounting frameless solar panels comprising: an upper plate having a top plane and a bottom plane having a centrally located aperture; a lower plate having a top plane and a bottom plane having centrally located aperture; a spacer having a top plane, a bottom plane, a first vertical surface and a second vertical surface; wherein the spacer has a centrally located aperture therethrough; a rail insert fastener system; and a plurality of cushions; whereby the aperture in the upper plate, spacer, and lower plate align to form a passage.
 11. The apparatus of claim 10, wherein the bottom plane of the upper plate and the upper plane of the lower plate have a groove configured to the top plane and the bottom plane of the spacer.
 12. The apparatus of claim 10, wherein the bottom plan of the upper plate, the top plane of the lower plate and the first vertical surface have a cushion attached thereto.
 13. The apparatus of claim 10, wherein the rail insert fastener system comprises a fastener and an insert, wherein the fastener traverses the passage and is secured to the insert.
 14. A process for mounting frameless solar panel modules comprising the steps of: a. preparing a first solar module panel module comprising the steps of: i. inserting a solar panel into an apparatus for mounting frameless solar panels wherein the apparatus comprises an upper plate having a top plane and a bottom plane having an aperture proximal to a first end, a lower plate having a top plane and a bottom plane having an aperture proximal to a first end, a spacer having a top plane, a bottom plane, a first vertical surface and a second vertical surface, wherein the spacer has a centrally located aperture therethrough, a fastener system, a plurality of cushions, a bracket having a long axis with a top plane and a bottom plane, wherein the bracket has a long axis which terminates at a first notched end and a second notched end, wherein the first notched end is on the top plane and the second notched end is on the bottom plane of the long axis, wherein the first notched end and the second notched end has an elongated opening in the direction of the long axis of the bracket, wherein the brackets have assembly apertures parallel to the long axis proximal to the first notched end and the second notched end, wherein the top plane is attached to the bottom plane of the lower plate and a rail insert fastener system, whereby the aperture in the upper plate, spacer, and lower plate align to form a passage, ii. traversing the passage formed by the aperture in the upper plate, spacer, lower plate, and assembly aperture with a first member of the fastener system, and iii. compressing the upper plate, the lower plate and the bracket by attachment of a second member of the fastener system to the first member of the fastener system; b. aligning the assembly apertures of a first notched end of a bracket of the first module to a second notched end of a bracket of a second module prepared by step a; c. traversing the elongated opening by a first member of the rail insert fastener system; and d. securing the first notched end bracket of a first module to a second notched end of the second module by attachment of a second member of the rail insert fastener system within a rail. 